Steven Szymeczek on DfAM Education and Workforce Development with 3D Printing Mentality
Steven Szymeczek on DfAM Education and Workforce Development with 3D Printing Mentality
3D Printing Mentality (3DPM) is a non-profit organization that aims to foster the development of the next generation of 3D printing professionals. Through various creative opportunities, 3DPM helps individuals to overcome knowledge barriers and become empowered in their communities.
Additionally, 3DPM is dedicated to equipping individuals with the skills necessary to make a meaningful impact in the rapidly growing field of 3D printing, with a specific focus on Design for Additive Manufacturing (DFAM) skillsets.
Members of 3DPM are excited to share their passions for the industry with others. The “3d printing mentality” is a product of sharing each of our individual career lessons multiplied by the collective group knowledge. With a focus on DFAM, our collaborative programs aim to equip individuals with the tools and understanding necessary to excel in advanced design, engineering, and additive manufacturing.
My name is Steven Szymeczek, current Board Member and President of 3D Printing Mentality. My journey and the origin of 3DPM, began in 2011,as a recent graduate of Mechanical Engineering. I had little understanding of 3D Printing technology and its potential applications. At the time, many universities were just beginning to integrate 3D printing into their curriculums, and I missed the opportunity to learn about it in my own school's lab. My first exposure to 3D printing came in the form of researching job postings that required experience with Sterolithography. At the time I had to research the term cause I honestly had no clue what it was.
It wasn't until I read an article in Popular Mechanics magazine later that year did I truly begin to grasp the significance of 3D printing in design, engineering, and manufacturing. As I learned more about its capabilities, I became increasingly convinced of its potential for revolutionizing many industries. This realization marked the beginning of my journey with my own “3D Printing Mentality”, as I became dedicated to sharing this knowledge and passion with others.
A few years later I started a new role as a Design Engineer for an aircraft interiors company. In this position, I used my knowledge of CAD and design for manufacturing to create various components that balanced both aesthetic and structural requirements for aircraft and passenger weight loads. Through this role, I was introduced to prototyping with 3D printing and even some production parts. However, I found that the traditional design and engineering practices I was using resulted in producing the same traditional geometries and methods.
This desire to expand my opportunities and skillset led me to start my own side business, Penumbra Engineering, with a friend and colleague from my university, Dean Pierce. Over time, this side business grew into a full-time opportunity where we focused on product development utilizing 3D printing technology. This experience further solidified my passion for 3D printing and my desire to share knowledge with others.
Five to six years ago, the term 'Generative Design' was relatively unknown in the industry. At Penumbra Engineering, we were fortunate to get our hands on early versions of the Autodesk software and were able to glimpse the possibilities that lay ahead. It became clear to me that the skillsets of the future for design and engineering would be closely tied to the use of these new design tools in conjunction with Additive Manufacturing.
In 2018, I was invited to speak at Autodesk University about a customer use case utilizing Generative Design for a ruggedized enclosure design. It was exciting to see the interest and enthusiasm around this topic, but many people were still figuring out how to apply these skillsets to real-world applications.
Fast forward to the end of 2021, where I found myself working as Head of Applications Engineering for a service bureau, where I continued to develop customer and colleague interest in design for additive manufacturing. However, the lack of DFAM skillsets and even definitions of what it meant for different 3D Printing technologies was still very lacking. I continued to struggle to find a good educational platform to enable those looking to develop critical skillsets.
In my free time, my oldest son and I enjoyed working on various 3D printing projects together. At one point, he expressed a need for a custom backpack clip for school, so we began experimenting with different designs, from simple ones to topology optimized designs.
Coincidentally, during this time, I also had the opportunity to give a talk on Design for Additive Manufacturing at Boise State University. Several faculty members encouraged me to sponsor a Senior Engineering Capstone. I shared the topology optimized clip project developed for my son, and this became the inspiration and the beginning of our first Engineering Capstone sponsorship.
3D Printing Mentality was officially established as a non-profit organization in early 2022, with the help of fellow board members Zack Richter and Tim Brown. Both bring their diverse backgrounds to the table, helping to create a platform that people can support and get behind. We combine our passion for 3D Printing with core skills in design, engineering, applications, and even marketing.
Our launch was in support of a Boise State University Engineering Capstone project, which aimed to optimize a climbing carabiner for Additive Manufacturing through Generative Design and Simulation. This project served as the foundation for our mission to empower individuals to overcome knowledge barriers, become leaders in their communities, and make a meaningful impact in the growing industry of 3D printing.
During the first semester, the students were introduced to various additive manufacturing technologies and design techniques. They delved into the different types of existing climbing carabiners, their uses, and how they are validated for functionality. Using Fusion 360 Generative Design, they began to create initial shapes and concepts based on the standard loads defined for carabiners. Additionally, they ran initial simulations to validate their models and assumptions, providing a solid foundation for further development.
During the second semester, the team shifted their focus to using Ntopology for the design process. They established a feedback workflow that utilized non-linear analysis from ANSYS to create scalar point maps. These maps were then used as input for Ntopology to drive the development of a graded Gyroid lattice with a partial external shell. The loads used in this process were based on the ASTM International Standards F1774 − 20 “Standard Specification for Climbing and Mountaineering Carabiners”, ensuring that the final design met industry standards.
The team gained access to a Markforged Metal X to manufacture the final parts. The metal material extrusion process, which typically doesn't use lattices except for infill, was used to print gryoid shapes through several experiments. Fused Deposition Model(FDM) prototypes helped the team fine-tune the design and printing parameters and develop a final workflow.
The team manufactured a series of final carabiners and put them through ASTM tests using an Instron Tensile tester. To account for uncertainty, the team built in a margin, which resulted in the successful passing of all tests.
The team examined the parts after the test and identified areas for improvement. The capstone project will be re-conducted in Fall 2023, and the format will be further refined and modified based on the team's findings.
3DPM continues to support initiatives, providing opportunities for students to participate in further non-profit activities and serve as mentors in future projects. The goal is to foster a continuous learning environment, where everyone can learn from one another and create the best programs possible. Additionally, 3DPM will continue to support Boise State University's metal additive carabiner design project and is looking to support an additional orthotic/prosthetic capstone in Fall 2023.
Currently, 3DPM is collaborating with sponsor Mach One to support Arizona State University's American Solar Challenge project. The project involves designing and building a one-seater solar-powered car that will participate in an cross country endurance race of 1500 miles. 3DPM's role is to assist the team in identifying parts that can be efficiently 3D printed to optimize the car's performance.
In addition to growing the mentor and volunteer base, we are excited to announce Matt Shomper of Marle Tangible has joined the board early this year. He will help expand the reach of 3DPM and computational design centric programs.
If you are interested in getting involved with 3DPM through donation, volunteering, or sponsorship, please visit our website for more information.
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